Apparatus for winding cores



Nov. 23, 1943, D. G. MARLOW 2,334,880

' APPARATUS FOR WINDING CORES Filed Jan. 21, 1942 6 Sheets-Sheet 2 Fig.5.

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Nov. 23, 1943. D. G. MARLOW APPARATUS FOR WINDING CORES 6 Sheets-Sheet {1 Filed Jan. 21, 1942 hvvuyro? DOUGLAS Geo/P65 MARLow J f FOR THE F/PM A TTO/PNL'KS.

6 Sheets-Sheet 6 D. G. MARLOW APPARATUS FOR WINDING CORES Filed Jan. 21, 1942 Nov. 23, 1943.

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hvvuvroe 'DouaL/qs GEORGE MARLOW A TTOANLKS.

U H 6 m T w P H, C a K Patented Nov. 23, 1943 2,334,880 APPARATUS FOR WINDING CORES I Douglas George Marlow,

or to National Technical Altadena, Calif., assign- Laboratories, South --Pasadena, Calif., a corporation of California Application January 21, 1942, Serial No. 427,581 23 Claims. (Cl. 57-6) My invention relates to the winding of wire and the like with special reference to for helically winding filaments on elongated cores, and is directed specifically to an improved apparatus and method for the quantity production of such a wound core. The term filament is herein used in a broad sense as including an element formed of a material capable of flexing sufficiently to be wound on a core, whether or not the material is electrically conducting. 1

While my invention is applicable broadly to winding problems in various arts, it is being initially employed for the fabrication of helically wound electrical resistance elements. I elect to describe my invention as so applied, since such a disclosure will be adequate guidance for employing the invention in other arts and for other purposes.

The general object of the invention is to provide a reliable and automatic high speed apparatus for helically winding a filament onto an elongated core.

The apparatus includes rotary means for moving the core longitudinally through a processing zone and a second rotary means for winding the filament onto the traveling core in the processing zone, and certain objects of the invention relate to these two rotary means. One of these objects is to provide automatic control for the relative speeds of the two rotary means lto the end that'the winding operation may be carried out with the filament fed to the periphery of the traveling core at a desirable angle.

For compact winding, the. "not only be taut to a required degree'iiiut must be fed to the traveling core at .an angle that is slightly acute relative to the direction of core movement, the slightly acute' angle being necessary to cause the filamenti'n approaching the periphery of the core to crowd against the last laid turn of'the filament. While the feed angle may varywithin an'appreciable range of angles, compactness in,'the winding of the filament is lost if the feed angle is too large, and, on the other hand, feeding the wire at too small an angle, causes the filament to climb upon the previously laid turns.

One object of my invention is to provide automatic means-to change either the speed of the winding operation or the speed of the core travel whenever the angle of feed approaches one of the limits of the range of desirable feed angles thereby to avoid departures from that range. In the preferred form of my invention I vary the procedures speed of the core travel in response to variation of the angle of winding feed.

A further object sought in the preferred form of the invention is to provide automatic means to stop both of said rotary means, thereby to stop both the winding operation and the travel of the core whenever the filament being fed to the core departs from the above-mentioned range of angles or whenever the filament breaks.

Certain objects of my invention relate to the specific problem of controlling one of the two rotary means in response to variation in the angle of winding-feed. Among these objects in various practices of my invention are: to provide a suitably sensitivecontrol member responsive to the angle of winding-feed; to provide control circuits adequately responsive to said control member; to provide in the control arrangement an adjustable motor circuit, in which circuit the adjustment is shifted automatically whenever the winding-feed angle approaches one of the limits of the selective range of angles; to provide in the control arrangement a motor circuitin which approach of the winding-feed angle to a limit not only results in a shift of the aforesaid adjustment, but also results in temporary corrective changes; to provide a main motor for both said rotary means with the driving transmission to one of the rotary means adjustable in response to changes in the windingfeed angle; and to provide a main motor for directly driving one of the two rotary means together with an automatically adjustable auxiliary or differential motor cooperative with the main motor to drive the other of the two rotary means.

Another group of objects relates to the prob lem of producing a particular type oi electrical resistance element comprising an insulationcoated resistive conductor helically .wound on a helical core. These objects include: to provide means having the dual function of forming the core to helical configuration and of drawing the unformed core through a processing zone; to provide a means and method for bonding the helicaleiement to the core; to provide a means and method for winding a core compactly to a predetermined maximum cross-sectional confiuration; and to provide a means and method for removing a portion of the coating from the coated winding to provide an exposed path along the finished resistance element.

The above and other objects of my invention will be apparent in my more detailed descripas indicated by the line |2-il of tion to follow, taken with the accompanying drawings.

In the drawings, illustrative only:

Fig. 1 is a side elevation of my apparatus;

Fig. 2 is a front elevation of the apparatus;

Fig. 3 is a vertical section on an enlarged scale taken as indicated by the line 8-4 of Fig. 2;

Fig. 4 is a fragmentary plan view partly in section showing a control assembly responsive to the winding-feed angle of the filament;

Fig. 5 is a transverse section taken as'indicated by the line H of- Fig. 4;

Fig. 6 is a longitudinal section taken on the broken line 8-8 of Fig. 4;

Fig. 7 is a transverse section taken as indicated by the line i-l of Fig. 4;

Fig. 8 is a longitudinal section taken as indicated by the line H of Fig. 4;

Fig. 9 is a transverse section taken as indicated by the line 9-.l of Fig. 4;

Fig. 10 is an enlarged side elevation partly in section of an emergency stop switch included in the apparatus:

Fig. 11 is an enlarged section through a portion 01' the apparatus taken as indicated by the line |l-Il of Fig. 1,' or the line lI-ll of Fig. 17;

Fig. 12 is an enlarged horizontal section taken Fig. 13 is an enlarged section taken as indicated by the line li-li of Fig. 1;

Fig. 14' is an enlarged section taken as indicated .by the line I 4-44 of Fig. 3;

Fig. 15 is a section taken as indicated by the line iB-li of Fig. 14;

Fig. 16 is an enlarged horizontal section taken as indicated by the line l8ll of Fig. 2;

Fig. 17 is an enlarged portion of "Fig. 1 with certain parts shown in section;

Fig, 18 is a view similar to Fig. 17 on a reduced scale showing a modified gear arrangement;

Fig. 19 is a perspective view of an electrical resistance element produced by the preferred form of my apparatus; and

Fig. 20 is a wiring diagram of an electrical arrangement that may be incorporated in the apparatus.

oi the preferred form General arranue ment The purpose of the specific apparatus shown in the drawings is to produce in quantity electrical resistance elements of the type disclosed in the copending application Serial No. 399,300. filed June 23, 1M1, by Henry H. Cary and Douglas George Marlow, entitled Variable resistor."v Such a resistance element, shown here in Fig. 19, comprises an insulated resistive conductor 20 helically wound on a core II, the core 2| beingpreferably a relatively heavy wire formed to helical configuration. The resulting unit is wound helically to form the resistance element shown in Fig. "19. The insulating coating of the resistive conductor II is removed to expose the metal of the resistive conductor along a helical contact path 22 on the inside or outside oi the completed resistance element, the purpose of the path being to permit a movable contact (not shown) to make electrical contact with the conductor 20.

The principal elements of the apparatus shown in Figs. 1 and 2 include a spool II for supplying the core 2|, a receptacle 2! for coatwhich are to be taken as g power transmission to ing the core with shellac or other adhesive ma terial, and a winding mechanism generally designated by the numeral 28 that winds the insulated conductor 20 on the core 2|, preferably while the shellac on the core is still tacky. The winding mechanism 20 includes a spool 21, a winding frame II, and two feed pulleys II in the frame for leading the insulated conductor 20 to a winding station in the lower end of the frame. After the core II is wound with the conductor 20, the previously mentioned contact path 22 is produced by leading the wound core against a coating-removal mechanism generally designated by the numeral 'll. Fimlly, the core carrying the helical winding is engaged by a forming mechanism generally designated 32 which has the function not only of forming the core into a helix but also of causing the core to move longitudinally through the apparatus.

A main motor It drives the winding mechanism 2| through a drive belt II and a sheave It and also drives the forming mechanism 32 in cooperation with a diiferential motor 31, the the forming mechanism including differential gearing in a gear case II and a vertical shaft 40. Control of the relation between the rate at which the insulated conductor 20 is wound on the core II and the rate of longitudinal movement of the core is governed by the rate or rotation of the differential motor 31, since the speed of the forming mechanism 32 is the resultant of the speed of the main motor and of the speed of the diii'erential motor. The means for regulating the speed of the differential motor 31 includes control means responsive to changes in the angle of feed of the conductor 20 to cludes associated electrial cabinet II.

the core 2i and indevices in a control The core coating means From the spool 23, which is rotatably carried by a pair of standards 42, the core M is led upward across the periphery of a relatively broad guide roller 43 and between a pair of grooved guide rollers 45. The guide rollers 43 and 45 are carried by a bracket 46 which in turn is mounted on a vertical frame 41. The vertical frame 41, on which various mechanisms of the apparatus are mounted, may comprise simply a vertical channel-iron carried by two brackets II, the brackets being mounted on a. building wall or column i0. v 4

A switch generally designated ii for automaticaliy stopping the apparatus whenever the core 2| breaks or' runs out may be placed near the guide rollers 43 and 45 and may be constructed as best shown in Fig. 10. The switch II includes an arm 52 pivotally mounted on the bracket 40 to swing against the traveling core 2|, the arm carrying a roller II in contact with the core. The arm 52 is urged laterally downward by a suitable leaf-spring 55 but is normally held against such movement by the traveling core. When the core 2| breaks or runs out, the arm I2 is released to carry a'contact II on the arm against a stationary contact I1, thereby closing a stop circuit.

From the guide rollers l8 and II thecore is led through a packing gland 58 in the bottom of the previously mentioned receptacle 2! that contains the shellac for coating the core. The receptacle 2! is supported on a standard 60 that extends outwardly from the apparatus frame 41 and the receptacle is provided with a cover hav- The winding mechanism As'best shown in Fig. 3 the winding frame 26 of the winding mechanism 26 is fixed to the lower end of a tubular stub shaft 62 and comprises an upper cross-bar 63, a lower channel-shaped cross-bar 65, and a pair of vertical tubuiarmembers 66 interconnecting the two cross-bars. The

tubular shaft 62, which carries the previously mentioned drive sheave 36, is rotatably supported by a pair of ball-bearings 61 that are mounted in a horizontal bracket 66, the bracket being anchored to the vertical apparatusframe 61. De-

pending from the bracket 63 is an arcuate support 16 for four brush assemblies .(Fig. 16) 1I,' 12, 13, and 14 that electrically cooperate respectively with four spaced rings (Fig. 3) 15, 16, 11, and 16 carried by a collar 16 on the rotary winding frame 28. The function of these brushes and rings will be explained later.

'- To support the previously mentioned spool 21 inside the rotary windingframe 26, a'tubular spindle 86 is fitted into the hollow stub shaft 62.

Botatably supported bya ball-bearing 6| on the spindle 86 is a spool sleeve 62, at the lower end of which is a spool-supporting split collar 83. To change a spool 21, the operator loosens a screw 65 to swing the lower cross-bar 65 to one .side and then loosens a setscrew 6.6 to remov the split collar 63 from the spool sleeve. f

From the spool 21 the insulated conductor 26, which is. preferably enamel-covered resistance wire, is led laterally outward to the pair-of grooved feed. pulleys 36, mounted in one of the tubular members-66 of the winding frame 23.- Each of the two grooved feed pulleys 36 is constructed and mounted in the manner indicated by Figs. 3, 14, and 15. Each'pulley 36 is rotatably carried by a small spindle 66, the spindle having screw threads 6| engaging the tubular frame member 66; Extending laterally from the pulley 36 to rotate therewith on the spindle 66 extending fingers I66 that slidingly engage opposite sides of the insulated conductor 26 as the conductor approaches the traveling core 2| at the winding station. The switch arm I61, which is on the grounded side of a circuit, carries at its end a laterally extending contact 6 in the path of which is an upper stationary contact III and a lower stationary contact. I I2. For insulation from the winding frame the lower contact H2 is mounted in an insulating bushing H3 and the upper contact III is mounted in a plate 6 of insulating material.

If the rate of travel of the core 2| through the winding station is excessive relative to the rate at which the conductor 26 is wound onto the core, the feed angle of the insulated conductor relative to the core will decrease and the movin contact 6 will touch the lower stationary contact 2 to close a control circuit for reducing the speed of core travel. On the other hand, if the rate of core travel lags relative to the winding rate, the winding-feed angle will increase and the movable contact II6 will touch the upper stationary contact III to close a control circuit having the is an extension 62 terminating in a disc 33, the 5 disc being provided with a facing 66 .of leather or other suitable material. Pressing against the facing to serve as a brake on a rotation of the pulley 36 is a second disc 66 keyed to the spindle 66, the pressure being provided by a bowed leaf- 1 spring 61 backed by an adjustable nut 63 on the end of the spindle 66. The described adjustable brakes to retard the two feed pulleysare provided for the purpose of placingthe insulated conductor 26 under a desirable degree of tension as the insulated conductor is fed to the periphery of the core 2 I As the insulated conductor 26 leaves the lower pulley 36 to approach the traveling core 2|, it passes through a small control assembly generally designated I66 in Fig. 3. As shown in Figs. 4 to 8, the control assembly I66 includes a normal control lever IM and an emergency control lever I62 both retained on a stud I63 capped by a screw I65, thestud being mounted in the chan-' nel-shaped cross-bar 65 of the'winding frame. The normal control lever I6I, shown in plan in Fig. 4 and in side elevation in Fig. 8; may comprise a loop of stiff wire forming a response arm I63 and a switch arm I61. The'response arm 166 carries at its end a pair of spaced laterally function of accelerating the core. Both of the stationary contacts III and H2 are threaded for axial adjustment whereby the range of angles in which the switch arm I61 is operative may be varied at will. It will'be noted in Fig. 6 that the two stationary contacts are relatively closetogether, so that the two control circuits become effective in a relatively narrow range of feed angles. I

The emergency control lever I62 isconstructed and arranged in substantially the same manner as the above described normal control lever and in the same manner provides a response arm I I6 and a switch arm I I1, but the arms ofthe emergency control lever are disposed oppositely from the arms of the normal control lever. The response arm II6 of the emergency control lever has-two spaced fingers II6 for sliding engagement with the insulated conductor 26 and the switch arm II1 swings a contact I26 between an upper stationary adjustable contact I2I in the insulating plate H6 and a lower stationary ad- 'justable contact I22 in an insulating bushing I23. The emergency control lever I62 has the function of stopping the apparatus whenever the winding-feed angle exceeds a predetermined range and also has the function of stopping operation whenever the insulated conductor 26 is broken or runs out. The two stationary contacts I2I and I22 are therefore connected to suitable relays for stopping operation whenever the emergency "control lever I62 reaches a limit position and a suitable spring I25 is provided to urge the emergency control lever to one of its limit positions whenever the conductor breaks or rims out and thereby releases the control lever.

In the described. arrangement the two stationary contacts HI and I22 for stopping the apparatus are adjusted to permit a range of feed angles exceeding in both directions the range of feed angles within which the normal control lever I6I operates. Consequently the switch arm II1 of the emergency control lever takes an effective position only when the action of the normal control lever I6I fails to keep the windingrial or any exuded shellac. The orifice member may be designed for the further purpose of insuring that the finished product is uniformly within a predetermined maximum gauge in cross-sectional dimension. In the particular construction illustrated, a replaceable orifice member I21 is retained on the end of a metal tube I28 by a suitable bushing I30. The metal tube I28, which has a tubular glass lining I3I, is held fixedly along the axis of the winding frame 28 by a fixed arm I32 on the previously mentioned gear case 38. To permit removal of the metal tube I28 whenever desired, the metal tube fits slidingly into a bore I33 in the end of the arm I32 and is provided with a peripheral recess I35 for engagement by a transverselatch pin I36. The latch pin I36 is provided with a head I31 for manual manipulation and is releasably held in effective disposition of a leaf-spring I38.

The coating-removal mechanism The scraper means shown in Figs. 1, 2, l3, and l! is driven by a motor I40 mounted on the apparatus frame 41. The motor I40 through a belt I drives a. small sheave I42 keyed to a small countershaft I43, the countershaft being journaled in bearings I 45 on the end of a standard I46. The countershaft I43 is keyed to a. second sheave I41 that operates a belt I48 to drive a third sheave I50. The third sheave I50 is keyed to a second countershaft- I I that is journaled in bearings I52 on the end of an arm I53, the function of the countershaft I 5| being to drive a rotary abrading means I55. In the depicted construction the abrading means I55 is a wire brush but various scraping devices may be employed in various practices of the invention. The arm I53 that carries the rotary brush IE5 is rotatably mounted on a cylindrical portion I56 of the standard I46 in such manner that the arm is free to swing about the axis of the first countershaft I43, it being contemplated that the abrading brush I55 may be applied to either of the two opposite sides of the wound traveling core.

In my preferred arrangement suitable means is provided for accurately adjusting the angle of the arm I53 to position the rotary brush I55 accurately relative to the wound core. For the purpose of such adjustment I provide an adjustment arm I51 having a split lower end I58 embracing the cylindrical portion I56 of the standard I46, the split end of the arm being provided with a screw I60 that may be loosened to permit the adjustment arm I51 to swing and which may be tightened to hold the arm at selected positions.

The outer end of the adjustment arm I5! is cut away to form two fingers I 6 I that are in snug contact with opposite sides of an eccentric or adjustment cam I62. The eccentric I62 has a suitable adjustment knob I 63 for manual manipulation and is ioumaled in a bore I65 in the swingable scraper arm I53, the eccentric being retained by a suitable screw I66. Approximate adjustment of the rotary brush I55 relative to the wound core 2| is obtained by adjustment of the adjustmentarm I51 and then closer adjustment is obtained by carefully rotating the eccentric I62 to cause slight movement of the arm I53 relative to the fixed adjustment arm I51.

For accurate processing it is desirable to restrain the traveling wound core against lateral movement at the zone of scraper action. Above the standard I46 a vertical plate I61 extends outward from the apparatus frame 41 to support the previously mentioned forming mechanism 32.

the vertical plate I61 Mounted on the vertical plate I61 is a horizontal standard I68 having a cylindrical portion I10 at its outer end into which slidingly extends a guide tube I1I for the wound core. The guide tube IN is releasably retained by a thumb screw I12, and two diametrically opposite recesses I13 are provided for engagement by the thumb screw whereby the guide tube may be set in either of two diametrically opposite dispositions. To expose the traveling wound core to the abrading action of the brush I55, an extensive recess I15 is cut in one side of the guide tube I1 I, and .a longitudinal slot I16 is cut on the opposite side of the guide tube to permit a thin roller I11 to press against the wound core.

In the construction shown, the roller I11 is mounted in a slot I18 on the end of a small arm I80, and the arm is pivotally mounted on a small bracket I8I at the lower end of the guide tube. The arm I is yieldingly urged toward the axis of the guide tube by a suitable coiled spring I82 on a stud I83. The stud I83, which is mounted on the guide tube I1I, extends through an apertirre I85 in the arm I80 and carries a thumb nut I86 for manual adjustment of the spring pressure.

In the disposition of the scraper mechanism depicted in the drawings the insulation is removed from the wound core to provide a path of exposed metal on the outside of the finished product. metal lie inside the finished helix, the arm I53 is rotated about the countershaft I43 to the opposite side of the guide tube I1I,'and the guide tube is rotated 180 to a reverse position.

The final forming mechanism The forming mechanism 32 which is best shown in Figs. l1, l2, and 17 includes an am I81 that is removably mounted on the upper end of the vertical plate I61 in some suitable manner. For example, the arm may be releasably attached to the plate I61 by a bolt I88 extending through a bore I90 in the plate and may be held against rotation about the axis or the bolt by a projection I 9I seated in a second bore I92 in the plate. In the construction shown, the projection I9I is provided by the inner end of a stud I93 that is mounted on the arm- I81 to rotatably carry a relatively thin forming roll I95 and an associated gear I96 of substantially the same diameter. Both the forming roll I95 and the gear I96 are mounted on a hub member I81 having a flange I 98 and are connected with the hub flange by suitable screws 200. The hub member is releasably retained on the stud by the head of a. screw 20I. The forming roll I95 has a single peripheral groove 202 to receive the wound core and may be made 01' fibrous material to discourage slippage of the wound wire. For actuation of the forming roll I95 a small gear 203 (Figs. 12 and 17) in mesh with the gear I96 is keyed to the end of a driven shaft 205, the shaft extending through from gearing in a gear case 206 on the opposite side of the plate.

To press the wound core against the periphery of the forming roll I95, suitable means is provided such as a pair of circumferentially spaced pressure rolls 291 carried by studs 208 on the ends of a yoke 2I0. Preferably a spur gear 2 is attached face-to-face to each of the pressure rolls 201, the spur gears-being in mesh with the large gear I96 to cause the two pressure rolls to be driven in a positive manner at the same peripheral speeds as the forming roll I95. The two pressure rolls 201 cooperate with the forming roll If it is required that the path of exposed I35 1n the function of gripping the wound core to draw the core through the various processing zones and in the further function of forming the wound core to the final helical configuration.

The yoke 2III is carried by a hollow pressure rod 2I2 that is slidingly mounted in a guide sleeve 2I3, the guide sleeve being integral with a small adjustable plate 2I5. In the construction shown the adjustable plate 2I5 has a pair of slots 2I6 engaged by screws 2H, and a number of threaded bores 2I8 for the screws are provided in the arm I81 whereby the plate 2I5 may be adjusted to various posiitons along the length of the arm. To provide yielding pressure for urging the pressure rolls 281 against the periphery of the forming roll I85, a suitable coiled spring 220 may be confined in the hollow pressure rod 2 I 2 by a floating plunger 22I which is normally depressed by a pressure cam 222. The pressure earn 222 is joumaled in an extension of the plate 2J5, being rotatably retained by a screw 223, and is integral with an operating handle 225. By means-of the handle 225 the pressure cam may be rotated 180 between an effective position at which the two pressure rolls press against the forming roll and an ineffective position which permits the forming roll to be retracted for the threading of a wound core into the forming mechanism.

It is contemplated that the forming mechanism will include interchangeable members whereby the forming mechanism may be adapted to the forming of helixes of various diameters. Fig. 18, by way of example, shows a combigad gear and forming roll 226 substituted for the forming roll I35 and the associated gear I85, the purpose of the substitution being to adapt the apparatus for the production of resistant elements of smaller diameter. The change to the smaller diameter also requires lowering of the arm I81 and the substitution of a new yoke assembly. To provide for lowering the arm I81 to the new position, Fig. 17 shows the vertical plate I81 provided with a lower bore 238 to receive the bolt I88 and a second lower bore 23I to receive the previously mentioned projection I3I. The substituted yoke assembly shown in Fig. 18 includes a pair of combined gears and pressure rolls 232 on a yoke 233, the yoke being carried by a relatively long hollow pressure rod 235. The pressure rod 235 extends through the guide sleeve H3 and is controlled in the previously described manner by the pressurecam 222.

be employed in the preferred form of my invention that will cause the rotation of the difierential motor 31 to be added algebraically to the ro- 'tation of the main motor 33 whereby the resultant speed may be varied by, regulating the differential motor. In the arrangement shown, it is contemplated that the resultant rotation will be the arithmetic sum of the two motor rotations, the rotative effect of the diiferential motor being in the same direction as the rotation of the drive motor. Fixedly attached to the upper end of the tubular shaft 62 in the previously mentioned gear.

case 38 is a disc 238 (Fig. 3) carrying planet gears 231 on studs 238. The planet gears 231 mesh with a drive-gear 248 that is integral with a tubular shaft 2 and also mesh with a differential gear 242 of like diameter that is rotatably mounted on the tubular shaft 2. The drive gear 248 may have, for example, one more tooth than the differential gear 242, so that one revolution of the disc 235 causes the gear 248 to advance one tooth when the gear 242 is stationary. Integral with the difierential gear 242 is a worm gear 243 in mesh with a worm 245 that is on the inner end of a horizontal shaft 248. The horizontal shaft 246 extends to the outside of the gear case 33 and carries at its outer end a worm gear-241 (Fig. l) The difierential motor 31 which is supported by a standard 248 has a downwardly extending motor shaft 250 to which is keyed a worm 25I in mesh with the worm gear 241. Preferably the motor shaft 250 also carries a small fiy-wheel 252.

It is apparent that the rate at which the short tubular drive shaft 2 is rotated by the drive wheel 248 depends both upon the rate of travel of the two planet gears 231 about the axis of the tubular shaft and upon the rate of rotation of the differential gear 242. The train of mechanism for power transmission to the final forming mechanism 32 includes the following: a spur'gear 255 on the upper "end of the tubular shaft 24I (Fig. 3); two intermeshed gears 258 (Fig. 2) mounted on a bracket 251; the previously mentioned vertical shaft 48; a helical gear 258 (Fig. 12) on the upper end of the shaft 48' a second helical gear 268 on the end of'a sfii'b 'shaft 26I that extends into the gear case 288; an inner gear 282 keyed to the stub shaft inside the gear case; a fixed ring gear 263; a disc 265 in the gear case keyed to the inner end of the previously mentioned shaft 205; and a plurality of planet gears 266 carried by studs 261 on the disc 265, the planet gears being in mesh both with the inner gear 262 and the outer fixed ring gear 263.

The electrical arrangement The wiring diagram depicted in Fig. 20 is to be regarded as illustrative only, since numerous electrical arrangements may be designed for controlling the described apparatus. vIn the motor circuits one power lead 218-1s connected to he main drive motor 33. the differential motor 31, the motor I48 that drives the brush I55, and an adjustment motor 21I that is concealed in the previously mentioned control cabinet 4|. The other power lead 212 is connected to a contactor switch 213 of a circuit-breaker relay generally designated 215. In response to energizationof the circuit-breaker relay 215 the contactor switch 213 moves from an ineifective position to a position establishing contact with a switch element connected to a wire 216 that leads to a second terminal of the adjustment motor 2". Connected to the wire 215 is a branch wi're 211 extending to a contact of a starting relay gen- I erally designated 218, and also connected to the wire 216 is a resistance 288 providing a wire 28I for connection with a'complementary contact in the starting relay 218, the two contacts rheostat contact 380 carried by the worm to traverse a-resistance 3M. This contact 333 is connected to the wire 23! by a wire 332 acting to short-circuit the current around the lower portion of the resistance 33I.- In series with the rheostat 233 in the circuit through the diflerential motor 31 are a manually adiustablerheostat 333 and a ilxed resistance 333.

The various control circuits employed in the apparatus are energized by a battery 333, one terminal of which is grounded, the other termi nal being in series with a normally-closed, manually-operative stop switch 331. The control circult through a coil 333 01 the starting relay 213 is completed by a wire 3i! from the stop switch 331, the wire being broken by a normally open, manually-operative starting switch 3| l In addi-- tion to the contactor switch 232 for the motor circuit, the starting relay 213 has a contactor switch 3l2for the lower voltage control circuits, the arm or this contactor switch 312 being connected to a wire 3". When the coil 333 oi the relay 213 is energized, the arm of the contactor switch 3|2 engages a contact connected to a wire 3| 5 that is connected to the wire 3! between the stop switch 331 and the starting switch 3. When the starting relay is deenergized, the arm of the contactor switch 3l2 engages a contact connected to a wire 3i 3 leading to one terminal oi. the control winding 3" of an emergency control relay "1.

The circuit-breaker relay 213 provides a coil 3I3, one terminal of which is grounded. The other terminal is connected to the wire 3" through a resistance 323 and is connected by a wire 32! of the arm of a contactor switch 322 forming a part of the emergency control relay 3| 1. So long as the winding 3| 5' oi the emer-, gency control relay 3|. is energized, the arm of the contactor switch 322 presses against a contact connected to a grounded wire 323. In addition to the contactor switch 213, the circuitbreaker relay 215 has a second contactor switch 32 5, the arm of which in the energized position of the relay engages a contact connected to the wire 3l'3. through a wire 323 and, in the deenergized position of the relay, engages another contact connected through a wire 321 to the arm of the contactor switch 322 of the emergency control relay.

The circuit through the coil 3" of the emergency control relay 3" the previously mentioned brush 1| and ring 15 on the winding mechanism 23 and a wire 3 that leads to both of the stationary contacts I20 and HI associated with the switch arm Ill! 01' the previously mentioned emergency control lever I32. The switch arm H1 is connected to a wire 332 which extends to the ring 13, the corresponding brush 14 being grounded as indicated.

The diagram also shows the switch arm I31 oi the previously mentioned normal control lever lill, this switch arm being connected to the wire 332 and thus to the ring 13 and to ground. Likewise, this diagram shows the two stationary contacts Ill and 2 that cooperate with the switch arms. Associated with the contacts I II and I I2 are respectively an acceleration relay generally designated 335 and a retarding relay generally designated 333. The contact III is in circuit with an operating coil 331 of the accelerating relay through a wire 333, the ring 11, the brush 13, and a wire 343. In like manner the contact H2 is in circuit with an operating coil 34! of the retarding relay through a wire 342, ring '13, brush includes also a wire 333,

12, and a wire 343. The circuits through the two coils 331 and 3 are completed by a wire 345 that is connected both to the previously mentioned wire 3" and to a wire 343 leading to the arm of the contactor switch 325 of the circuit breaker relay. Each of the two coils 331 and 3 is shunted by a suitable fixed resistance 341.

One function of the accelerating and retarding relays 333 and 333 is to control the adjustable rheostat 233 through the medium of the adjustment motor 2" in response normal control lever lfll in the winding mechanism. Any suitable reversible motor may serve as the adjustment motor 21 I. The particular adiustment motor 21l indicated in the drawings is a shaded pole motor and is reversible by virtue oi circuits which short-circuit one or the other 01 its shading windings. Both 01' the shading winding circuits of the adjustment motor 21l have a common wire 343 and one of, the shadingcircuits includes a wire 353 in which is placed a limit switch "I while the other shading circuit includes a wire 352 in which is placed a limit switch 353. The two limit switches are adapted for operation by the traveling nut 233.

When the accelerating relay 335 is energized byiaction of the normal control lever llil, a contactor switch 355 connects the wire 343 with the wire 350 to drive the motor 21! in a direction to reduce the resistance oiIered by the rheostat 233 in the circuit of the differential motor 31; on the other hand, when the retarding relay 333 is energized by the normal control lever, a contactor switch 353 connects the wire 343 with the wire 352 to drive the adjustment motor 2" in the opposite direction for the purpose of increasing the resistance through the rheostat 233 thereby to reduce the speed of the diflerential motor 31.,

The accelerating and retarding relays 335 and 333 need have no additional function for the practice of my invention, but I prefer to employ them for the further purpose of momentarily reducing or increasing current flow through the differential motor 31 whenever the normal control lever Ill moves the switch arm I31 to one of its limit positions. The accelerating relay 335 is adapted when energized toshunt the fixed resistance 335 in the diflerential motor circuit, thereby to increase the current through the difrerential motor. The required shunt circuit includes a wire 351 from one side of the resistance 335, a wire 353 from the other side of the resistance and a contactor switch 363 associated with the accelerating relay 335 so that the shunt circuit is gized. I

For the purpose of temporarily reducing current through the difl'erential motor 31 in response to energization of the retarding relay 336 I provide another shunt circuit. One side of this second shunt circuit includes the wire 351 and a wire 36! extending to a contact'in the retarding relay. The other side of the shunt circuit includes a resistance 362, a wire 333 and the arm of a contactor switch 335 forming a part of the retarding relay that engages the contact to close the circuit when the relay is energized.

Operation of the apparatus In setting up the apparatus for operation, first a spool 01' the insulated conductor 20 is installed in the winding frame. Then the wire for the core 2| is threaded through the various parts of the apparatus including the feed rolls, the coatclosed whenever the relay is enering receptacle, the winding mechanisms, the

to movements of the" guide tube associated with the abrading brush, and the forming mechanism at the top apparatus. The insulated conductor is then led'to the winding station where a few turns are made on the core 2| by hand. The operator then closes the starting switch 8 and holds the switch closed until normal operation is attained, the operator in the meantime manipulating the adjustable rheostat 303 as may be required to cause the normal control lever to hover in the desired normal range of feed angles.

The energization of the starting relay 210 by the starting switch 3 causes the contactor switch 282 to interconnect wires 216 and 283 in the motor circuit through the resistance 200 and simultaneously causes the contactor switch in to connect the wire 3|: with the wire 5., the effect of the latter action being energization of the circuit-breaker relay 215 through wire "6, contact arm 325, wire 321, and wire 32L When the circuit-breaker relay is energized, the contactor'switch 210 completes the motor circuit by connecting the wire 212 to the wire 216. Si-

multaneously the contactor switch 325 electrically interconnects the wires 326 and 346 to keep-the circuit-breaker relay energized by the battery 306. When the operator releases the starting 'switch 3 to deenergize the starting relay 210,

the contactor switch 202 moves to its alternate position at which it still maintains the motor circuit (except that the resistance 280 is removed therefrom), and the contactor switch 3I2 shifts to its alternate position connecting the wire 3I3 to the wire 3I8. This latter action causes control of the motor circuits to be transferred from the starting switch 3 to the emergency control relay 3I1, theenergization of which is in turn controlled by the emergency control lever I02, such energization closing the contactor switch 322 and-" thusIby-passmg to'ground the energizing current otherwise flowing to the winding 3I8 of the circuit breaker relay 215 through the resistor 320.

against -'the contact III the accelerating relay 335jis energized to temporarily shunt the, resistance 305 and simultaneously to adjust the rheostat 280 in the direction of increased current flow.

On the other hand, whenever the change in the winding-teed angle swings the switch arm I01 againstthecontact H2, the retarding relay 036 is energized to adjust the rheostat 288 in the direction of decreased current flow, the relay simultaneously shunting current around the difl'erand whenever the winding-feed angle shifts beyond the desired range of angles in either direction. the switch arm I I1 of the emergency control lever I02 touches one of the contacts I20 and I2I to energize the emergency control relay 3 I 1 there-- by moving the contactor switch 022 to its circuit-closing position. As a result, the circuitbreaker relay 215 is deenergized by short-circuiting oi the coil 3I0. Deenergization or the circuit-breaker relay causes the contactor switch enever the winding-teed angle increases suf- 'flclentlyto cause the'switch arm I01 to swing Iii .The preferred form of my invention, which has I been described in detail herein for the purpose of disclosure and to illustrate the underlying principles, includes dispensable refinements and will suggest to those skilled in the art various changes and substitutions under my concept; I reserve the right to all such departures that properly'come within the scope of my appended claims. I

I claim as my invention:

1. An apparatus of the character described for winding a flexible member onto an elongated core, said apparatus including: means to feed said flexible member to the periphery of said core, driving means to rotate relatively said feeding means and said core; driving means to move said core longitudinally past said feeding meansgand means responsive to changes in the angle of feed of said flexible member to regulate the speed of one of said driving means thereby to keep the feeding angle within a desired range.

2. An apparatus of the character described for winding a flexible member onto an elongated core, said apparatus including: means to feed said flexible member to the periphery of said core; driving means to rotate said feeding means about said core; driving means to move said core longitudinally past said feeding means; and means responsive to changes in the angle of feed of said flexible member to stop both said driving means whenever the angle of feed departs from a predetermined range of angles.

3. An apparatus of the character described for winding a flexible member onto an elongated core, said apparatus including: a first'means to move said core longitudinally through a winding station; a second 'means to feed said flexible member to the periphery of said core helically at said winding station; a primary actuator to drive-one of said two means; a differential actuator cooperative with said primary actuator to drive the other of said two means at a resultant rate; and means responsive to. changes in the angle of feed of said flexible member at said winding station to regulate said differential actuator and thereby regulate the relative speed of said two means.

4. An-apparatus of the character described for winding a flexible member onto an elongated core, said apparatus including: a first-means to move said core longitudinally through a winding station; a second means to feed said flexible member to the periphery of said core helically at said winding station; a primary actuator to drive one of said two means; a motor cooperative with said primary actuator to drive the other of said two means at a resultant speed; adjustable means to regulate the driving effect of said motor on said other of said two means; means responsive to the angle of feed of said flexible member to automatically vary the setting of said adjustable "means; means to increase the energizing current through said motor temporarily in response to change of said angle of feed to a predetermined limit in one di ture rection; and means to decrease the energizing current through said motor temporarily in response to change of said angle of feed to a predetermined limit in the other direction.

5. An apparatus of the character described for winding a flexible member onto an elongated core,- said apparatus including: a first meansto move said core longitudinally through a wind ing station; a'second means to feed said flexible member to the periphery of said core helically at said winding station; a primary actuator to drive one of said two means; a motor cooperative with said primary actuator to drive the otherpf said two means at a resultant speed; a circuit for energizing said motor; a first means to-change the resistance in said-circuit in response to changes in the feed angle of said flexible member at said winding station to increase the current through said motor when said angle reaches one limit of a range of angles; and a secnd means to change the resistance in said circuit in response to changes in the feed angle of said flexible member to decrease the current through said motor when said angle reaches the other limit of said range of angles.

6. An apparatus of the character described for winding a flexible member onto an elongated core, said apparatus including: means to feed said flexible member to the periphery of said core; driving means 'to rotate relatively said feeding means and said core; driving means to move said core longitudinally past said feeding means: means to regulate the speed of one of: said driving means: a first control circuit operatively associated with said regulating means to increase said speed; a second control circuit operatively associated with said regulating means to decrease said speed; and means responsive to changes in the angle of feed of said flexible member to close said flrst circuit when said angle reaches one limit of a range of angles and to close said second circuit when said angle reaches the opposite limit of the range of angles.

7. An apparatus of the character described for winding a flexible member onto an elongated core,- said apparatus including: a spool wound with said flexible member; a rotary support carrying said spool, said spool and support having an axial passage; a first drivingmeans to draw said core longitudinally through said passage; a second driving means to rotate said support;

means carried by said support to feed said flexible member to the periphery of said core in such manner as to wind. said flexible member around Q said core as a plurality of helically-disposed turns in contact with each other; and means operatively connected to one of said driving means for automatically changing the speed thereof with respect to the other of said driving, means in response to changes in position of the point of initial contact of said flexible member with themriphery of said core.

8.. An apparatus for fabricating a resistance element having a helical winding on an elongated core, said apparatus including: a receptacle for coating material: means having an aperture dimensioned for the maximum cross-sectional dimension of the flnished resistance element: guide means for said finished resistance element means to draw said core longitudinally through said re-' ceptacle to receive a coating, then through said aperture and then through said guide means; rotary means to apply said' helical winding, to the coated core before the core enters said aperand means adjacent said guide means and contacting said helical winding exclusively of one side thereof for abrading same in a longitudinally-extending path on said one side thereof. 5 9. An apparatus for fabricating a resistance having a partially coated helical winding on an elongated core, said apparatus including: a receptacle for coating material; means to draw said core through said receptacle to receive a coating and then longitudinally past a winding station and a coating-removal station in succession; means to supply the winding material completely coated; rotary means to apply the completely coated winding to said core at said winding station; and means on one side the path of move ment of said core at said coating-removal station to remove the coating from said helical winding on one side of the wound resistance element. 10. An apparatus for fabricating a resistance having a partially coated helical winding on an elongated core, said apparatus including: a receptacle for coating material; means to draw said core through said receptacle to receive a coating and then longitudinally past a winding station and a coating-removal station in succession; means to supply the winding material completely coated; rotary means to apply the completely coated winding to said core at said winding station; abrading means on one side the path oi movement 01 said core at said coating-removal station to remove the coating from said helical winding on one side of the wound resistance ele ment; and means at said coating-removal station to limit lateral movement of the wound re-' sistance away from said abrading means.

11. An apparatus forfabricating a resistance comprising a helical winding on a helical core;

said apparatus comprising: means to direct the unformed core on a longitudinal path of move- 40 ment; rotary means to apply said helical windsegment oi the roll periphery for the dual purpose of, drawing the core along said path and 01' forming the wound core into the desired helix. that turn of the helix within-said peripheral groove acting to crowd previously-formed turns from the end of said ro 12. An apparatusfor-fabricating a resistance having a partially .coated helical winding on a helical core; saidapparatus including: means to direct the unfdrmed core on a longitudinal path of movement; means to supply completely coated winding material; rotary-means to apply said winding material in a helix to the periphery of the moving-unformed' core; means on one side the path of movement of said unformed core to remove the coating from said helical winding on one side after the winding is applied to the core; 65 a rotary forming means for the wound core having a cylindrical surface; and means to press the wound core onto the cylindrical surface of said rotary means for the dual purpose of drawing the core along said path and of forming the wound core into the desired helix.

roll being circular-and and meansto press the wound:

relationship with one of said posit temporarily fluid material on the moving unwound core; rotary means to feed the winding material to the periphery of the moving core at said winding station while said deposited material is on the core and before the deposited material hardens; and means responsive to the winding material at the winding station to regulate the speed of one of said rotary means automatically to maintain the feeding direction of the winding material within a predetermined range of feeding directions.

14. An apparatus for fabricating a resistance having a partially coated helical winding on a helical core, said apparatus including: a rotary means to form the wound core into a helix; means to press the wound core against said rotary means thereby to draw the unformed core past a winding station and coating-removal station in succession; means to deposit temporarily fluid material on the moving unwound oore rotary means to feed coated winding material to the periphery of the moving core at said winding station while said deposited material is on the core and before the deposited material hardens; and means on one side the path of movement or said core at said coating-removal station to remove the coating from said helical winding on one side of the wound resistance element.

15. An apparatus as set forth in claim 14 which includes means to regulate the speed or at least one of said rotary means in accordance with the rate at which the winding is applied to the core relative to the rate of core movement.

16. An apparatus of the character described for winding a flexible member onto an elongated core, said apparatus including; a first means to move said core longitudinally through a winding station; a second means to feed said flexible memher to the periphery of said core helically at said winding station; a primary actuator to drive one of said two means; a difierential actuator cooperative with said primary actuator to drive the other of said two means at a resultant rate: and means to regulate said differential actuator in response to changes in position relative to said winding station of the point of initial contact oi said flexible member with the periphery of said core.

17. An apparatus of the character described for winding a flexible member onto an elongated core, said apparatus including: feeding means for feeding said flexible member to the periphery oi said core; driving means for rotating relatively said feeding means and said core to wrap said flexible member around said core; driving means for moving said core in a longitudinal direction past said feeding means at such rate that the flexible member is wrapped helically in contacting turns about said core, said feeding means being disposed to feed said flexible member toward the periphery of said core at a slightly acute iced angle; control means responsive to a change in said feed angle; and means for operatively connecting said control means in speedmhanging driving means to compensate for said change in feed angle.

18. A combination as defined in claim 1 in which said means responsive to said angle oi. feed includes response arm means slidably engaging the flexible member as it advances toward the periphery of said core to move with changes in said angle of feed, and means for controlling the relative movement of said driving means in response to movement of said response arm means to keep the angle or feed within a predetermined range.

19. A combination as defined in claim 1 in which said means responsive to said angle of feed includes a response arm slidably engaging the flexible member as it advances toward the periphcry of said core, means for movably mounting said response arm, a first circuit including a switch means operated by movement of said response arm in one direction to modify the speed of one of said driving means, and a second circuit including a switch means operated by movement of said response arm in another direction to modify oppositely the speed of said one ofsaid driving means.

20. A combination as defined in claim 1 in which said means responsive to changes in the angle of teed of said flexible member includes additional means to stop both said driving means whenever the angle of feed departs from said desired range.

21. A combination as defined in claim 1 in which said means responsive to said angle of feed includes response arm means slidably engaging the flexible member as it advances toward the periphery of said core to move with changes in said angle of feed, means for controlling the relative movement of said driving means in response to movement of said response arm means to keep the angle of feed within a predetermined range, and means responsive to breakage 01 said flexible member and to deviations of said angle of feed from said predetermined range.

22. An apparatus for fabricating an element comprising a flexible member wound helically around an elongated core, said apparatus including: a receptacle for coating material; means for drawing said care through said receptacle to receive a coating of said coating material and then longitudinally past a winding station and an abrading station in succession; means for winding said flexible member helically around said core at said winding station to produce a woundcore element; and abrading means on one side oi thepath of movement of said wound-core element at said abrading station for abrading said wound-core element in a longitudinally-extending path on said one side thereof.

23. An apparatus for fabricating an element comprising a flexible member wound helically around an elongated core, said apparatus including: a receptacle for coating material; means for drawing said core through said receptacle to receive a coating of said coating material and then longitudinally past a winding station and an abrading station in succession; means for winding said flexible member helically around said core at said winding station to produce a woundcore element; abrading means on one side of the path of movement of said wound-core element at said abrading station for abrading said woundcore element in a longitudinally-extending path on said one side thereoi; and means for bending said wound-core element into the form of a helix with the abraded path facing radially with respect to the central axis of the helix.

DOUGLAS GEORGE MARLOW. 

